U.S. patent application number 15/414240 was filed with the patent office on 2018-07-26 for self-stick insulation and methods.
The applicant listed for this patent is JOHNS MANVILLE. Invention is credited to Jawed Asrar, Thomas John Fellinger, Ames Kulprathipanja, Guodong Zheng.
Application Number | 20180208806 15/414240 |
Document ID | / |
Family ID | 62905750 |
Filed Date | 2018-07-26 |
United States Patent
Application |
20180208806 |
Kind Code |
A1 |
Fellinger; Thomas John ; et
al. |
July 26, 2018 |
SELF-STICK INSULATION AND METHODS
Abstract
A method of using a self-stick insulation. The method includes
providing a piece of insulation product with an adhesive coating.
The adhesive coating includes polystyrene-maleic anhydride (SMA)
and/or polyacrylic acid (PAA); an alcohol amine; and at least one
of a polyvinyl alcohol and a starch. The adhesive coating is then
activated with liquid water. Once the adhesive coating is active,
the insulation product is attached to a surface with the adhesive
coating.
Inventors: |
Fellinger; Thomas John;
(Littleton, CO) ; Zheng; Guodong; (Highlands
Ranch, CO) ; Kulprathipanja; Ames; (Broomfield,
CO) ; Asrar; Jawed; (Englewood, CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
JOHNS MANVILLE |
Denver |
CO |
US |
|
|
Family ID: |
62905750 |
Appl. No.: |
15/414240 |
Filed: |
January 24, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04B 1/7666 20130101;
C09J 2301/408 20200801; B32B 17/02 20130101; C09J 125/08 20130101;
C09J 133/02 20130101; C09J 103/00 20130101; C09J 2425/00 20130101;
C09J 2403/00 20130101; C09J 2433/00 20130101; C08K 5/17 20130101;
B32B 2307/304 20130101; C09J 7/38 20180101; C09J 7/22 20180101;
C09J 7/32 20180101; C09J 2429/00 20130101; C09J 129/04 20130101;
C09J 2403/00 20130101; C09J 2425/00 20130101; C09J 129/04 20130101;
C09J 2403/00 20130101; C08L 25/08 20130101; C09J 2433/00 20130101;
C08K 5/17 20130101; C09J 2425/00 20130101; C09J 129/04 20130101;
C08L 33/02 20130101; C09J 2429/00 20130101; C08K 5/17 20130101;
C09J 2429/00 20130101; C09J 2403/00 20130101; C09J 2433/00
20130101; C09J 103/00 20130101; C08L 25/08 20130101; C08K 5/17
20130101; C09J 2425/00 20130101; C09J 2429/00 20130101; C09J
2429/00 20130101; C09J 2433/00 20130101; C09J 103/00 20130101; C08L
33/02 20130101; C08K 5/17 20130101 |
International
Class: |
C09J 125/08 20060101
C09J125/08; C09J 133/02 20060101 C09J133/02; C09J 5/00 20060101
C09J005/00 |
Claims
1. A self-stick insulation, comprising: an insulation product, the
insulation product comprising: a length; a width; a thickness; and
a first major surface and a second major surface that extend the
length and the width of the insulation product; and an adhesive
coating applied to the first major surface of the insulation
product, the adhesive coating comprising: at least one of
polystyrene-maleic anhydride (SMA) and polyacrylic acid (PAA); an
alcohol amine; and at least one of a polyvinyl alcohol and a
starch; wherein the adhesive is activated with the application of
liquid water.
2. The self-stick insulation of claim 1, wherein the alcohol amine
comprises at least one of monoethanolamine (MEA) and diethanolamine
(DEA) and triethanolamine (TEA).
3. The self-stick insulation of claim 1, wherein the
polystyrene-maleic anhydride (SMA) and/or polyacrylic acid (PAA),
the alcohol amine, and the polyvinyl alcohol and/or starch comprise
30-50% by weight of the adhesive coating at the time the adhesive
coating is applied to the insulation product.
4. The self-stick insulation of claim 1, wherein the pH of the
adhesive coating is 5.5-7.5.
5. The self-stick insulation of claim 1, wherein polystyrene-maleic
anhydride (SMA) and/or polyacrylic acid (PAA) comprise 30-55% by
weight of the adhesive coating at the time the adhesive coating is
applied to the insulation product.
6. The self-stick insulation of claim 1, wherein the polyvinyl
alcohol and/or starch comprise 30-60% by weight of the adhesive
coating at the time the adhesive coating is applied to the
insulation product.
7. The self-stick insulation of claim 1, wherein the adhesive
coating comprises a non-continuous and non-uniform coating atop the
first major surface.
8. The self-stick insulation of claim 1, wherein the insulation
product comprises 1-8% by weight of the adhesive coating after the
adhesive coating is applied and dried to the insulation
product.
9. The self-stick insulation of claim 1, further comprising a facer
coupled to the insulation product with the adhesive coating.
10. The self-stick insulation of claim 1, comprising a heating,
ventilation, and air conditioning (HVAC) system with the self-stick
insulation product.
11. A method of making a self-stick insulation, comprising:
providing a piece of insulation product; applying a water activated
adhesive coating to a surface of the insulation product, the water
activated adhesive coating comprising: at least one of
polystyrene-maleic anhydride (SMA) and polyacrylic acid (PAA); an
alcohol amine; water; and at least one of a polyvinyl alcohol and a
starch; and drying the adhesive coating to evaporate the water to
form a dry adhesive coating layer on the surface.
12. The method of claim 11, comprising coupling a facer to the
insulation product with the water activated adhesive coating.
13. The method of claim 11, wherein the adhesive coating is applied
to a first major surface to form a non-continuous and non-uniform
coating on the first major surface.
14. The method of claim 11, wherein the alcohol amine comprises at
least one of monoethanolamine (MEA), diethanolamine (DEA) and
triethanolamine (TEA).
15. The method of claim 11, wherein the viscosity modifier
comprises at least one of styrene maleic anhydride copolymer (SMA)
and polyacrylic acid.
16. The method of claim 11, wherein the insulation product
comprises 1-8% by weight of the adhesive coating after the adhesive
coating is applied and dried to the insulation product.
17. A method of using a self-stick insulation, comprising:
providing a piece of insulation product with an adhesive coating,
wherein the adhesive coating comprises: polystyrene-maleic
anhydride (SMA) and/or polyacrylic acid (PAA); an alcohol amine;
and at least one of a polyvinyl alcohol and a starch; activating
the adhesive coating with liquid water; and attaching the
insulation product to a surface with the adhesive coating.
18. The method of claim 17, comprising repositioning the insulation
product on the surface before the adhesive coating dries.
19. The method of claim 17, wherein the alcohol amine comprises at
least one of monoethanolamine (MEA), diethanolamine (DEA) and
triethanolamine (TEA).
20. The method of claim 17, wherein the viscosity modifier
comprises at least one of polystyrene-maleic anhydride (SMA) and
polyacrylic acid (PAA).
Description
FIELD OF THE INVENTION
[0001] This disclosure generally relates to insulation.
BACKGROUND OF THE INVENTION
[0002] This section is intended to introduce the reader to various
aspects of art that may be related to various aspects of the
present invention, which are described and/or claimed below. This
discussion is believed to be helpful in providing the reader with
background information to facilitate a better understanding of the
various aspects of the present invention. Accordingly, it should be
understood that these statements are to be read in this light, and
not as admissions of prior art.
[0003] Pre-formed insulation products (batts, blankets, boards,
etc.) are applied to various structures and equipment using a
variety of fastening techniques. For example, in wood framed wall
applications, faced batt insulation are typically stapled to
perimeter framing members of each cavity via a stapling flange on
the facing. Similarly, un-faced batt insulation used for framed
walls (wood or steel stud) is typically held in place with a
friction fit. For crawl spaces, lightning rods or other mechanical
fastening devices are typically used to hold the insulation in
place. Foam boards are generally glued to framing members and/or
fastened with nails or other fasteners. Insulation may also be
coupled to surfaces using adhesives. The adhesives are generally
applied to the insulation right before installation. Typical
adhesives include solvent-based products, hot melts, and pressure
sensitive adhesives. Unfortunately, these adhesives may be
expensive and/or require the use of personal protective equipment
(PPE) to protect workers from burns, volatile organic compounds
(VOC), etc.
BRIEF SUMMARY
[0004] The present disclosure is directed to various embodiments of
self-stick insulation. In an embodiment, a self-stick insulation
product defines a length, a width, and a thickness. A first major
surface and a second major surface extend the length and the width
of the insulation product. An adhesive coating is applied to the
first major surface of the insulation product. The adhesive coating
includes polystyrene-maleic anhydride (SMA) and/or polyacrylic acid
(PAA); alcohol amine; and at least one of a polyvinyl alcohol and a
starch. The adhesive is activated with the application of liquid
water.
[0005] In another embodiment, a method of making a self-stick
insulation is described. The method includes providing a piece of
insulation product. A water activated adhesive coating is then
applied to a surface of the insulation product. The water activated
adhesive coating includes polystyrene-maleic anhydride (SMA) and/or
polyacrylic acid (PAA); alcohol amine; water, and at least one of a
polyvinyl alcohol and a starch. The adhesive coating is dried to
evaporate the water to form a dry adhesive coating layer on the
surface. To activate the adhesive, water is applied to the
coating.
[0006] In another embodiment, a method of using a self-stick
insulation is provided. The method includes providing a piece of
insulation product with an adhesive coating. The adhesive coating
includes polystyrene-maleic anhydride (SMA) and/or polyacrylic acid
(PAA); alcohol amine; and at least one of a polyvinyl alcohol and a
starch. The adhesive coating is then activated with liquid water.
Once the adhesive coating is active, the insulation product is
attached to a surface with the adhesive coating.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Various features, aspects, and advantages of the present
invention will be better understood when the following detailed
description is read with reference to the accompanying figures in
which like characters represent like parts throughout the figures,
wherein:
[0008] FIG. 1 is a perspective view of an embodiment of an
insulation product;
[0009] FIG. 2 is a perspective view of an embodiment of an
insulation product with an adhesive coating on a major surface;
[0010] FIG. 3 is a top view of an embodiment of an insulation
product with an adhesive coating;
[0011] FIG. 4 is a top view of an embodiment of an insulation
product with an adhesive coating;
[0012] FIG. 5 is a top view of an embodiment of an insulation
product with an adhesive coating;
[0013] FIG. 6 is a cross-sectional view of an embodiment of an
insulation product with an adhesive coating;
[0014] FIG. 7 is a perspective bottom view of an embodiment of an
insulation product with a facer;
[0015] FIG. 8 is a perspective view of an embodiment of an
insulation product coupled to an object;
[0016] FIG. 9 is a cross-sectional view of an embodiment of an
insulation product coupled to an object; and
[0017] FIG. 10 is a flowchart of a method of making a self-stick
insulation product.
DETAILED DESCRIPTION
[0018] One or more specific embodiments of the present invention
will be described below. These embodiments are only exemplary of
the present invention. Additionally, in an effort to provide a
concise description of these exemplary embodiments, all features of
an actual implementation may not be described in the specification.
It should be appreciated that in the development of any such actual
implementation, as in any engineering or design project, numerous
implementation-specific decisions must be made to achieve the
developers' specific goals, such as compliance with system-related
and business-related constraints, which may vary from one
implementation to another. Moreover, it should be appreciated that
such a development effort might be complex and time consuming, but
would nevertheless be a routine undertaking of design, fabrication,
and manufacture for those of ordinary skill having the benefit of
this disclosure.
[0019] The embodiments discussed below include insulation products
that are "self-stick." The term self-stick refers to the insulation
products ability to bond or adhere to an object without the need to
apply an adhesive or glue immediately before pressing the
insulation product on the object for which bonding is intended. The
term self-stick does not imply that an adhesive is not used to
adhere the insulation product to a surface, but rather, that a user
need not apply the adhesive immediately before installation.
Because the user is not required to apply the adhesive immediately
before installation, installation time is reduced, the user is less
exposed to various chemicals (e.g., VOCs), and is protected from
potential burns (e.g., hot melt adhesives).
[0020] The embodiments described herein are generally referred to
as insulation products which may include fibrous insulation and/or
insulation boards. These terms are used merely for convenience in
describing the embodiments and are not meant to limit the invention
to any one type of insulation product unless indicated. These terms
may include any insulation type products, which could be made of
various fibers, foams, and the like. Common types of insulation
products include fiberglass, mineral wool, slag wool, rock wool,
foam or other insulation boards, and the like, which may include
facers. The disclosure also uses the terms "re-adherable" or
"rebondable" to describe how liquid water (i.e., non-gaseous or
vapor water) may be applied to the dried adhesive to activate the
adhesive for bonding, adhering, or coupling with another
object.
[0021] In operation, the dry adhesive film or coating activates in
the presence of liquid water and not in the presence of humidity.
For example, the thin film or coating of the dry adhesive on the
insulation or flange may be moistened with a fine water mist with a
sprayer, sponge, and the like, and allowed a few seconds to change
phase from a sold to a gel or viscous liquid. The insulation
product can then be placed and pressed in position, held for
several seconds, and released. After the moistened adhesive gel or
liquid dries, a bond forms between the insulation product and the
application surface that holds the insulation product in place. In
some embodiments, a surface (e.g., a wall) intended for the
insulation product may be wet with a sponge or sprayer and then the
insulation product positioned and pressed against the surface to
adhere the insulation to the surface.
[0022] In some embodiments, the adhesive may be applied to a
surface of the insulation product by spraying the adhesive onto the
surface and/or onto a flange of the insulation product via a spray
header and pump assembly. The application of the adhesive may occur
during an insulation manufacturing process or by a secondary
fabricator. The applied adhesive forms a thin film or coating of
adhesive on the insulation surface. In another embodiment, the
adhesive can be applied using an adhesive-filled trough and by
pulling the insulation mat through the trough at a controlled speed
such that a film coating or layer forms on the insulation product's
surface.
[0023] The wet adhesive film, layer, or coating may then be dried
via a curing oven, infrared oven, some other heat source, or air
dried before the insulation product is further processed and
packaged, such as by rolling the insulation product for shipment to
another facility. In some embodiments, the dry adhesive coated
insulation product may then be shipped to in weather tight
packaging to avoid exposure to liquid water and thus reactivation
of the adhesive during shipment and/or storage.
[0024] In some embodiments, a facer material may couple to the
insulation product using the water activated adhesive coating. The
facer material may be a paperboard or cardboard material (e.g.,
kraft paper), foil, scrim, polymer material, and the like, or any
combination thereof (e.g., foil, scrim, kraft (FSK)). In some
embodiments, the insulation product may be transported to a
separate facility after the adhesive is applied and dried. The
separate facility may then bond the facer material to the
insulation product by reactivating the adhesive with liquid water.
In some embodiments, the insulation product may be precut into
desired shapes before shipment to facilitate future
installation.
[0025] During installation installers wet the dry adhesive layer or
coating with liquid water and apply the insulation product to one
or more objects. For example, the installers simply need a water
application device, such as a sprayer, sponge, etc. to apply liquid
water to reactivate the adhesive. The installers may therefore
avoid handling additional glues and/or adhesives while installing
the insulation product and the associated exposure to volatile
organic compounds (VOCs).
[0026] The adhesive coating enables the insulation product to
couple to a variety of objects with or without the use of clips,
pins, staples, etc. These objects may include metal surfaces such
as ducts, pipes, machine components (e.g., HVAC systems, cars). In
some embodiments, the insulation product may be installed between
studs or joints (e.g., metal, wood) of a building or home. In
another embodiment, the insulation product may be adhered to garage
door panels (e.g., plastic, wood, metal) to insulate a home or a
building's garage.
[0027] When the dry adhesive layer or coating is wetted and pressed
against an object, the adhesive may have a "working time" or tack
time in which the installer is able to adjust the position of the
insulation product relative to the object. In other words, the
adhesive may have a period of time before it completely or
significantly sets and the insulation product is firmly held in
place. The adhesive's working time allows the installer to move or
shift, or even remove, the insulation product in case of
misalignment, improper installation, and the like. For example, the
working time or tack time may be less than 30 seconds. In another
embodiment, the installer may have 15 seconds or less, 10 seconds
or less, 5 seconds or less before the adhesive sets and adheres to
the object. In still another embodiment, the adhesive may become
tacky within 4-8 seconds to the point that the insulation product
may be applied to an object's surface and remain in place.
[0028] As explained above, the adhesive reactivates when liquid
water is applied. In some embodiments, the adhesive may become
sufficiently tacky upon an application of as little as 1%, 2%, 3%,
4%, 5% liquid water by weight of the insulation product. In another
embodiment, the adhesive may become sufficiently tacky upon an
application of water between about 5% and 15% by weight of the
insulation product. This range allows the adhesive to become tacky
without becoming overly fluid and/or without saturating the
insulation product with water and thereby increasing the weight
that must be supported by the adhesive and/or the drying time. As
described herein, the water may be applied by spraying a fine mist
over the dry adhesive layer, film, or coating, or by applying the
water with a sponge. Although the adhesive is reactivated upon the
application of liquid water, the adhesive may not reactivate even
when subjected to high humidity and high heat conditions. For
example, the adhesive may remain in the nonadherable or nonbondable
state even when subjected to a relative humidity as high as 90% or
more at 100 degrees Fahrenheit. As such, the insulation product may
be shipped to and installed in areas of high heat and humidity
without negatively affecting the insulation product's
performance.
[0029] The adhesive may be applied to the insulation product so as
to form a non-continuous and/or non-uniform layer, film, or coating
atop the insulation product's surface. For example, the adhesive
material may be applied to the insulation product's surface in a
patterned arrangement (e.g., S-pattern, parallel or crossing lines,
honeycomb pattern, dot pattern, splat pattern, and the like). Once
applied and dried, the adhesive coating may comprise between 1% and
8% by weight of the insulation product. In other embodiments, the
dry adhesive layer, film, or coating may comprise between 3%-6%,
1%-4%, 3%-4% by weight of the insulation product. In still other
embodiments, the dry adhesive coating may be 1-6 grams per square
foot, 2-4 grams per square foot, 3-4 grams per square foot, etc.
These small amounts of adhesive coating on the insulation product
enable rapid reactivation and bonding while reducing costs and
providing sufficient support for the insulation product.
[0030] The adhesive is formed by combining polystyrene-maleic
anhydride (SMA) and/or polyacrylic acid (PAA); an alcohol amine; a
polyvinyl alcohol and/or starch; and water to form an adhesive
mixture. It is this mixture that is then sprayed, roll-coated, etc.
onto the insulation product. The polystyrene-maleic anhydride (SMA)
and/or polyacrylic acid (PAA); alcohol amine; polyvinyl alcohol
and/or starch. These components may be referred to as solids in
this adhesive mixture. In some embodiments, the percentage of
solids in the adhesive mixture is between 30-50% with water making
up the remainder of the mixture. The high percentage of solids in
the adhesive mixture facilitates a rapid drying of the adhesive
(i.e., reduced tack or set time) by reducing the amount of water
that needs to evaporate. In another embodiment, the percentage of
solids in the adhesive mixture may be between 35-40%. The
combination of these materials in the proportions disclosed below
reduce flammability, smoking, and corrosion of the adhesive
enabling the use of the adhesive in the applications discussed
above and below.
[0031] In operation, the components of the adhesive mixture serve
specific purposes that either facilitate formation of the adhesive
and/or give the adhesive specific properties. For example, the
alcohol amine serves as a pH stabilizer, fire retardant, and a
corrosion inhibitor. The alcohol amine component of the adhesive
mixture may include at least one of monoethanolamine (MEA);
diethanolamine (DEA) and triethanolamine (TEA). In some
embodiments, the percentage of the alcohol amine component of the
adhesive mixture may be 10-15% by weight of the solids in the
adhesive mixture. It has been found that too much alcohol amine in
the adhesive enables moisture in the air to activate the adhesive,
while too little reduces the fire resistance of the adhesive.
Accordingly, the preferred percentage of alcohol amine should be
11-13% by weight of the solids in the adhesive mixture to reduce
and/or block moisture in the air from unintentional activation of
the adhesive while still providing fire resistance. In some
embodiments, the alcohol amine enables the adhesive coating to pass
the E84 fire test.
[0032] The polyvinyl alcohol and/or starch component of the
adhesive mixture provides the adhesive with all or a majority of
its tackiness/stickiness. This component may be 30-60% by weight of
the solids in the adhesive mixture to provide an adequate amount of
tackiness/stickiness. The polyvinyl alcohol may also increase the
flexibility of the adhesive. In other words, the polyvinyl alcohol
may reduce and/or prevent the adhesive from becoming to brittle
and/or cracking after and/or before installation. Polyvinyl alcohol
may also assist in resisting activation of the adhesive from
moisture in the air.
[0033] The other major portion of the adhesive mixture may include
at least one of polyacrylic acid (PAA) and styrene maleic anhydride
copolymer (SMA). This portion of the adhesive mixture may be 30-55%
by weight of the solids in the adhesive mixture in order to reduce
the viscosity of the mixture to ensure adequate mixing of all the
components of the adhesive mixture. In embodiments that contain SMA
or/and PAA, the SMA or/and PAA may contribute to the overall
tackiness/stickiness of the adhesive.
[0034] In some embodiments, the SMA and/or PAA, may have a relative
low molecular weight in order to lower the viscosity. It has been
found that too high molecular weight of SMA and PAA increases the
viscosity, while too low of a molecular weight reduces the
tackiness and adhesion. The molecular weight of SMA and PAA may be
500-5,000 (g/mol).
[0035] In some embodiments, SMA may be pre-hydrolyzed in water at
elevated temperature to be water soluble. The ammonia may be added
during the hydrolysis reaction. For example, ammonia may operate as
a hydrolysis accelerator in the reaction that forms the adhesive
mixture. In embodiments that use ammonia, the ammonia may be
2.5-3.5% by weight of the adhesive mixture.
[0036] In some embodiments, the pH of the adhesive mixture may be
adjusted to an optimal pH. It has been found that if adhesive
mixture has a low pH corrosion may increase and that if the pH is
to high the adhesion/tackiness may decrease. An optimal pH for the
adhesive mixture may therefore be between 5.5-7.5 pH.
[0037] As explained above, the adhesive may couple an insulation
product to a variety of surfaces. Below are various tables
illustrating tests conducted with the adhesive material under
various conditions and with different materials.
[0038] Table 1 reflects the test results of the adhesive using the
standards of ASTM C 916 (Standard Specification for Adhesives for
Duct Thermal Insulation).
TABLE-US-00001 TABLE 1 Required Testing Material
Requirement/Allowable Status D 903 Bonding Strength Galvanized
Steel/ 0.5 lb/in. Pass (Ambient) Canvas/SSA D 903 Bonding Strength
Galvanized Steel/ 0.5 lb/in. Pass (24 hrs. @ 95% RH) Canvas/SSA D
903 Bonding Strength Galvanized Steel/ 0.5 lb/in. Pass (7 days @
160.degree. F.) Canvas/SSA C 916/D1151 Bonding Retention Galvanized
Steel/ .gtoreq.75% fiber bonding Pass (90 days @ 160.degree. F.) JM
Micromat/SSA E 84 Surface Burning Cement Board/SSA 25/50
Flame/Smoke Pass Characteristics C 916 Edge Burning 1'' JM
Micromat/SSA No residual flame > Pass 3 sec. C916 Edge Burning
1'' JM Tuf-Glas/SSA No residual flame > Pass 3 sec. C 916
Storage Stability SSA No property change In Process after 6 months
Additional Property Testing Material Test Result Status Solid
Content SSA 40% NA Viscosity SSA 1418 cpoise @ 22.degree. C. NA Dry
Reactivation SSA w/Micromat, ~6-10 sec. NA Tuf-Glas & Duracore
Repositioning Time SSA w/Micromat, ~10-20 sec. NA Tuf-Glas &
Duracore Bonding Time SSA w/Micromat, Partial - 20-60 sec. NA
Tuf-Glas & Duracore Full - 24 hrs. Color SSA Amber NA Odor SSA
Mild sweet/sour smell NA
[0039] Table 2 reflects the test results of the adhesive using the
standards of ASTM C 1071 (Standard Specification for Fibrous Glass
Duct Lining Insulation).
TABLE-US-00002 TABLE 2 Requirement/ Material Allowable Status
Required Testing C 655 Corrosiveness Carbon Steel/ No corrosion
> Pass 95% RH, 120 F., 96 hrs. Tuf-Glas control material C 1104
Water Vapor Sorption Tuf-Glas/SSA .ltoreq.3% by wt. Pass C 1104
Water Vapor Sorption Micromat/SSA .ltoreq.3% by wt. Pass C 1104
Water Vapor Sorption Duracore/SSA .ltoreq.3% by wt. Pass C 1338
Fungi Resistance Micromat/SSA No fungal growth Pass C 411
Temperature Duracore/SSA No flame, smoke, Pass Resistance, 250 F.
glowing, delamination, etc. UL 181 Erosion Resistance Micromat/SSA
No material loss Pass at 2500 fpm air velocity for 6 hrs. C 1304
Odor Emission Micromat/SSA Not objectionable Pass 150 F., 30 min. E
84 Surface Burning Characteristics Micromat/SSA .ltoreq.25/50
Flame/Smoke Pass E 84 Surface Burning Characteristics Tuf-Glas/SSA
.ltoreq.25/50 Flame/Smoke Pass Apparent Thermal Conductivity Not
tested - NA NA adhesive has no influence Sound Absorption
Coefficients Not tested - NA NA adhesive has no influence G 22
Bacteria Resistance Micromat/SSA No bacterial growth Pass NFPA 259
Combustion Characteristics Tuf-Glas/SSA .ltoreq.3500 Btu/lb. Pass
NFPA 259 Combustion Characteristics Micromat/SSA .ltoreq.3500
Btu/lb. Pass Additional Testing C 665 Corrosiveness Galvanized
Steel/ No corrosion > Pass 95% RH, 120 F., 96 hrs. Tuf-Glas
control material C 665 Corrosiveness Galvanized Steel/ No corrosion
> Pass 95% RH, 120 F., 96 hrs. Micromat control material C 665
Corrosiveness Galvanized Steel/ No corrosion > Pass 95% RH, 120
F., 96 hrs. Duracore control material C 1617 Accelerated
Corrosiveness Carbon Steel/ No corrosion > Pass Tuf-Glas control
material
[0040] Table 3 reflects the test results of the adhesive using the
standards of ASTM C 1290 (Standard Specification for Flexible
Fibrous Glass Blanket Insulation Used to Externally Insulate HVAC
Ducts).
TABLE-US-00003 TABLE 3 Material Requirement/Allowable Status
Required Testing C 655 Corrosiveness Carbon Steel/ No corrosion
> Pass 95% RH, 120 F., 96 hrs. Tuf-Glas control material C 1104
Water Vapor Sorption Tuf-Glas/SSA .ltoreq.5% by wt. Pass C 1104
Water Vapor Sorption Micromat/SSA .ltoreq.5% by wt. Pass C 1104
Water Vapor Sorption Duracore/SSA .ltoreq.5% by wt. Pass C 1338
Fungi Resistance Micromat/SSA No fungal growth Pass C 411 Hot
Surface Duracore/SSA No flame, smoke, Pass Performance, 250 F.
glowing, delamination, etc. C 1304 Odor Emission Micromat/SSA Not
objectionable Pass 150 F., 30 min. E 84 Surface Burning
Characteristics Micromat/SSA .ltoreq.25/50 Flame/Smoke Pass E 84
Surface Burning Characteristics Tuf-Glas/SSA .ltoreq.25/50
Flame/Smoke Pass Thermal Resistance Not tested - NA NA adhesive has
no influence Water Vapor Permeance Not Applicable to NA NA adhesive
coatings Additional Testing C 665 Corrosiveness Galvanized Steel/
No corrosion > Pass 95% RH, 120 F., 96 hrs. Tuf-Glas control
material C 665 Corrosiveness Galvanized Steel/ No corrosion >
Pass 95% RH, 120 F., 96 hrs. Micromat control material C 665
Corrosiveness Galvanized Steel/ No corrosion > Pass 95% RH, 120
F., 96 hrs. Duracore control material C 1617 Accelerated
Corrosiveness Carbon Steel/ No corrosion > Pass Tuf-Glas control
material
[0041] Turning now to the figures, FIG. 1 is a perspective view of
an embodiment of an insulation product 10. As illustrated, the
insulation product 10 is fibrous insulation 12 (e.g., insulation
blanket made from fiberglass). The fibrous insulation 12 has a
length L, a width W, and a thickness H. The fibrous insulation 12
also includes a first major surface 14 and a second major surface
16, which typically extends for the length and width of the fibrous
insulation 12. In some embodiments, a facer 18 may couple to the
first major surface 14, the second major surface 16, and/or any
other surface of the insulation product 10. As explained above, the
fibrous insulation 12 uses an adhesive to couple to an object. The
adhesive is applied to the first and/or second major surface 14, 16
to form a coating, film, or layer of adhesive. For example, the
adhesive may be placed on the first major surface 14 in order to
couple a facer 18 to the fibrous insulation 12. In some
embodiments, the second major surface 16 may also be coated with
adhesive enabling the fibrous insulation 12 to couple to an object
(e.g., HVAC component, pipe, duct, etc.). In other embodiments, the
insulation product 10 may not include a facer 18 but instead
adhesive on the first and/or second surfaces 14, 16. At the time of
use, the adhesive is reactivated with liquid water and adhered to
the surface of an object. As the adhesive dries, the adhesive
couples to the insulation product 10 to the surface and/or
object.
[0042] FIG. 2 is a perspective view of an embodiment of an
insulation product 10 with an adhesive coating 30. As illustrated
in FIGS. 2-6, the adhesive coating 30 may be applied to the
surfaces 14, 16 so as to form a non-continuous and/or non-uniform
coating, film, or layer on the insulation product 10. The
description of "non-continuous" means that the coating, layer, or
film is not a single or solid (i.e., essentially unbroken) coating,
layer, or film. The description of "non-uniform" means that the
pattern of the coating, layer, or film is random. A potential
advantage of a non-continuous and/or non-uniform coating, layer, or
film is that less adhesive material is used while providing
sufficient adhesion or bonding to a surface. In other embodiments,
a continuous and/or uniform coating, layer, or film of the adhesive
may be applied to the insulation product as desired. In some
embodiments, the adhesive film, layer, or coating may be about
0.010 to 0.020 inches thick.
[0043] In FIG. 3, the adhesive coating 30 may be applied to the
insulation product 10 with a plurality of way lines 40 (e.g., an
S-shaped pattern). In FIG. 4, the adhesive coating 30 may be
applied in a series of parallel and/or crisscrossing straight lines
50. And in FIG. 5, the adhesive coating 30 may be applied in a
repeating dot pattern, or in some embodiments an irregular splat
pattern. In still other embodiments, the adhesive coating 30 may be
applied in other patterns such as honeycomb. By not completely
covering the surfaces 14, 16 less adhesive may be used while still
enabling the insulation product to adhere to the surface of an
object.
[0044] FIG. 6 is a cross-sectional view of an embodiment of an
insulation product 10. As illustrated, the adhesive layer 30
couples to the fibers 60 (e.g., fiberglass). The adhesive layer 30
may adhere to the insulation product 10 through adhesion to the
actual fibers 60 and/or by adhering to itself around the fibers 60
(e.g., wrapping around the fibers 60).
[0045] FIG. 7 is a bottom view of an embodiment of an insulation
product 10 with a facer 18. The insulation product 10 may be
similar to any of the insulation products described herein (e.g.,
fibrous insulation, board, etc.). However, the insulation product
10 includes a facer 18 that is wider than the width of the
insulation product 10 to form a flange 70 on a side 72 of the
insulation product 10. While not shown, the insulation product 10
may include one or more additional flanges 70 on other sides of the
insulation product 10. For example, the insulation product 10 may
include four flanges 70 one for each side of a square or
rectangular insulation product 10. Differently shaped insulation
products 10 may include different numbers of flanges 70 (e.g., 1,
2, 3, 4, 5, 6, etc.). In some embodiments, the flanges 70 may
extend from the insulation product 10 by 0.5, 1, 1.5, 2, 2.5, 3, or
more inches.
[0046] The adhesive material 30 described herein may be applied to
first and/or second sides 74, 76 so that one or both sides of the
flanges 70 include a layer, coating, or film of the adhesive
material 30. This allows the flange 70 to be wetted and pressed
against an object surface to adhere or bond the insulation product
10 to the object. In some embodiments, the second major surface 16
may also be coated or layered with the adhesive 30 to allow these
portions of the insulation product 10 to also adhere or bond with
an object's surface. In some embodiments, the entire surface on the
side 74 of the facer 18, or a substantial portion thereof, may be
coated with the adhesive 30 prior to coupling the facer 18 to the
insulation product 10. The adhesive 30 may bond the facer 18 to the
insulation product 10 in addition to providing the flange 70 that
is adherable or bondable to other objects.
[0047] FIG. 8 is a perspective view of an embodiment of an
insulation product 10 coupled to an object 90. As explained above,
the insulation product 10 is bonded or adhered to the surface 90 by
wetting the dry adhesive layer, coating, or film 30 with liquid
water and then placing the insulation product 10 against the object
90 for a period of time (e.g., 1-10 seconds). After the period of
time, the adhesive 30 bonds the insulation product 10 to the
surface of the object.
[0048] FIG. 9 illustrates an insulation product 10 bonded or
adhered between studs or joists 100 of a wall 102, ceiling, or
floor. The insulation product 10 includes a facer 18 that may
adhere to the studs 100 via the adhesive coating, layer, or film of
the flanges 70. Specifically, liquid water may be applied to the
flanges 70 so that the flange's adhesive coating forms a gel or
viscous fluid that adheres the flanges 70 to the studs 100 and/or
inner stud walls. In some embodiments, the sides and/or a top
surface of the insulation product 10 may include an adhesive
coating and may also adhere the insulation product 10 to the studs
100 and/or wall. In some embodiments, the studs 100 may be deeper
than the insulation product 10 so that a cavity 104 is formed
between a top surface of the insulation product 10 and the wall
102. The insulation product 10 may be pushed between the studs 100
to reduce or eliminate the cavity 104.
[0049] The adhesive allows the insulation product 10 to be coupled
between the studs 100 without the use of clips, pins, staples, and
the like. When the insulation product 10 is used in a crawl space
or a ceiling, the adhesive may couple the insulation product 10
between joists 100 without using a lightning rod, which is
typically used to hold the insulation product 10 in place. The
adhesive greatly simplifies installation because an installer may
simply wet the flanges 70, and/or side or top surface, let the
adhesive tack up for a few seconds, and then crawl underneath the
joists 100, and press the insulation product 10 in position. The
adhesive will then set up and hold the insulation product 10 in
position. The adhesive offers a similar advantage in coupling
insulation products to steel studs, ducts, pipes, etc.
[0050] Referring now to FIG. 10, illustrated is a method 120 of
making a insulation product and attaching the insulation product to
an object. At block 122, an insulation product is provided. As
described herein, the insulation product has a length, a width, a
thickness, and a first major surface and a second major surface
which each extend for the length and width of the insulation
product. At block 124, an adhesive is applied to one or more
surfaces of the insulation product. As explained above, the
adhesive may be applied to the insulation product using any number
of patterns (e.g., wavy lines, straight lines, crisscrossing lines,
orthogonal lines, honeycomb pattern, a dot pattern, a splat
pattern). At block 126, the adhesive coating is dried (e.g., air
dried, passed through an oven, etc.) to evaporate the water in the
adhesive so that the adhesive coating forms a dry layer on the
insulation product. In a dried state, the adhesive may not adhere
or bond with another object. In order to reactivate the adhesive
for bonding, liquid water is applied to the adhesive coating, block
128. After reactivation of the adhesive coating, the insulation
product may then be bonded to an object (e.g., wood, metal,
plastic, etc.), block 130.
[0051] In some embodiments, the dry layer of adhesive may comprise
between 0.1% and 10% of the fibrous insulation blanket by weight,
although a range of between 2% and 8% is more common. In other
embodiments, the dry layer of adhesive may comprise between 1% and
6%, between 3% and 5%, or about 3% to 4% of the fibrous insulation
product by weight. In some embodiments, the amount of adhesive
applied may depend on the application process. For example,
continuous or relatively continuous adhesive coatings may have a
dry layer of 8% or 10% by weight of the blanket while an S pattern
application could comprise less than 2% by weight of the blanket.
In some embodiments, the dry adhesive layer may become re-adherable
or rebondable to other objects upon application of water between
about 1% and 15%, 5% and 25%, or about 10% by weight of the
insulation product. In some embodiments, upon the subsequent
application of water, the adhesive may have a tacky or working
state that allows the fibrous insulation product to be repositioned
with respect to an object that the adhesive is applied to. The
adhesive may be in the tacky or working state between 1 second and
30 seconds, after the application of liquid water. The adhesive may
change to the tacky or working state within 10 seconds, within 5
seconds, and the like upon the application of water. Once the
adhesive dries, the adhesive may remain nonadherable or nonbondable
to other surfaces even when subjected to a relative humidity of up
to 100%.
[0052] While the invention may be susceptible to various
modifications and alternative forms, specific embodiments have been
shown by way of example in the drawings and have been described in
detail herein. However, it should be understood that the invention
is not intended to be limited to the particular forms disclosed.
Rather, the invention is to cover all modifications, equivalents,
and alternatives falling within the spirit and scope of the
invention as defined by the following appended claims.
* * * * *